EP0869518A1 - Drosselspule - Google Patents

Drosselspule Download PDF

Info

Publication number
EP0869518A1
EP0869518A1 EP97909597A EP97909597A EP0869518A1 EP 0869518 A1 EP0869518 A1 EP 0869518A1 EP 97909597 A EP97909597 A EP 97909597A EP 97909597 A EP97909597 A EP 97909597A EP 0869518 A1 EP0869518 A1 EP 0869518A1
Authority
EP
European Patent Office
Prior art keywords
core
coil
choke coil
terminal
air
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP97909597A
Other languages
English (en)
French (fr)
Other versions
EP0869518B1 (de
EP0869518A4 (de
Inventor
Toshiyuki Nakata
Koji Nakashima
Katsunori Omura
Kiyoshi Takagi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Corp
Original Assignee
Matsushita Electric Industrial Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from JP8281965A external-priority patent/JPH10125545A/ja
Priority claimed from JP28196396A external-priority patent/JP3346188B2/ja
Application filed by Matsushita Electric Industrial Co Ltd filed Critical Matsushita Electric Industrial Co Ltd
Publication of EP0869518A1 publication Critical patent/EP0869518A1/de
Publication of EP0869518A4 publication Critical patent/EP0869518A4/de
Application granted granted Critical
Publication of EP0869518B1 publication Critical patent/EP0869518B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Images

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F37/00—Fixed inductances not covered by group H01F17/00
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/28—Coils; Windings; Conductive connections
    • H01F27/29—Terminals; Tapping arrangements for signal inductances
    • H01F27/292—Surface mounted devices

Definitions

  • the present invention relates to a choke coil utilized in electronic products both for consumer and industrial uses.
  • a power supply section particularly in a switching power supply, has struggled with the following three major demands: 1. accommodating to a higher switching frequency, 2. employing a higher density of parts mounting, particularly a surface mounting method, 3. accommodating to a large current responsive to a higher performance of semiconductor, etc.
  • a choke coil one of the major parts of the switching power supply, has been thus demanded for having a smaller loss, accommodating to a larger current, and being smaller and thinner to be used in the surface mounting.
  • FIG. 47 is an exploded perspective view
  • Fig. 48 is a perspective view depicting the coil incorporated with a closing magnetic core
  • Fig. 49 is a perspective view depicting a complete product
  • Fig. 50 is a cross section
  • Fig. 51 is a top view depicting the coil from which one magnetic core is removed.
  • the following elements are illustrated in the above Figs.: flat type wire 1 covered by an insulated material, an air-core coil 2, an inner turn 3 of the air-core coil 2, an outer turn 4 of the air-core coil 2, a terminal 5 of the inner turn 3, a terminal 6 of the outer turn 4, a center magnetic stool 7, an outer magnetic wall 8, a common magnetic base 9, a closing magnetic core 10 of magnetic field, an insulating paper 11, a window height 12 of the closing magnetic core 10.
  • the structure of the conventional thin-type choke coil is as follows:
  • the air-core coil 2 is formed by coiling the flat type wire 1.
  • the inner terminal 5 and the outer terminal 6 are coupled with an inner turn 3 and outer turn 4 of the air-core coil 2 respectively by e.g., soldering.
  • the air-core coil 2 and the insulating paper 11 are disposed around the center magnetic stool 7 of the closing magnetic core 10.
  • the inner terminal 5 coupled with the inside turn 3 of the air-core coil 2 is led out from a clearance between the aircore coil 2 and the common magnetic base 9 of the closing magnetic core 10, thus a thickness of the inner terminal 5 is added to the window height 12 of the closing magnetic core 10, whereby a dead space is produced in the window height direction.
  • a space factor lowers and the choke coil cannot be further slimmed.
  • the present invention aims to provide the thinner choke coil by lowering the height, and the choke coil which can accommodate to the larger current as well.
  • the choke coil according to the present invention comprises the following elements:
  • the air-core coil is disposed around the center magnetic stool of the closing magnetic core, and at least an inner terminal of the terminals is led out from a notch or an opening provided on the common magnetic base of the closing magnetic core.
  • the thickness of the inner terminal does not influence the window height.
  • the space factor increases, and the window height can be lowered, whereby the thinner choke coil is realized.
  • the thickness as well as the area of the inner terminal can be increased so that the choke coil can accommodate to the larger current.
  • Fig. 1 is an exploded perspective view of the choke coil in the first exemplary embodiment according to the present invention.
  • Fig. 2 is a perspective view depicting the air-core coil mounted to the terminal base illustrated in Fig. 1.
  • Fig. 3 is a perspective view of a completed product shown in Fig. 2.
  • Fig. 4 is a top view depicting the assembled elements illustrated in Fig. 3 including the air-core coil, the terminal base and E-shape magnetic core.
  • Fig. 5 is a cross section of the completed product shown in Fig. 4.
  • Fig. 6 is a perspective view depicting an example of a pin terminal.
  • Fig. 7 is a perspective view depicting an example of TU-shape magnetic core.
  • Fig. 8 is a top view depicting a modification of E-shape magnetic core.
  • Fig. 9 is a top view depicting the air-core coil mounted around the E-shape magnetic core.
  • Fig. 10 is an exploded perspective view depicting the choke coil utilized in the second exemplary embodiment of the present invention.
  • Fig. 11 is a perspective view depicting the air-core coil mounted to the terminal base illustrated in Fig. 10.
  • Fig. 12 is a perspective view depicting the assembled elements illustrated in Fig. 10 including the air-core coil, the terminal base and E-shape magnetic core.
  • Fig. 13 is a perspective view depicting an insulating paper incorporated into the status shown in Fig. 12.
  • Fig. 14 is a perspective view of a complete product depicted in Fig. 13.
  • Fig. 15 is a perspective view of the assembled elements illustrated in Fig. 10 including the air-core coil, the terminal base and E-shape magnetic core.
  • Fig. 16 is a cross section of the complete product depicted in Fig. 14.
  • Fig. 17A and Fig. 17B are a top view and a front view depicting the air-core coil before it is coiled.
  • Fig. 18 is a top view of the air-core coil depicted in Fig. 17.
  • Fig. 19 is a top view of another air-core coil.
  • Fig. 20 illustrates inconvenience in coupling the terminals of the air-core coil.
  • Fig. 21 illustrates a method of coupling the terminals where a spacer is used.
  • Fig. 22 is a cross section depicting an I-shape magnetic core having a cavity.
  • Fig. 23 is a cross section depicting inconvenience when the I-shape magnetic core does not have the cavity.
  • Fig. 24 is an exploded perspective view depicting a cylinder being separated from the terminal base.
  • Fig. 25 is an exploded perspective view depicting the air-core coil being incorporated into the cylinder.
  • Fig. 26A through Fig. 26C are a top view, side view and front view depicting the E-shape magnetic core.
  • Fig. 27A and Fig. 27B are a bottom view and a front view depicting the I-shape magnetic core.
  • Fig. 28A and Fig. 28B are a bottom view and a front view depicting another I-shape magnetic core.
  • Fig. 29 is an exploded perspective view of the choke coil utilized in the third exemplary embodiment according to the present invention.
  • Fig. 30 is a perspective view of a complete product depicted in Fig. 29.
  • Fig. 31 is a cross section of the complete product depicted in Fig. 29.
  • Fig. 32 is an exploded perspective view of the choke coil utilized in the fourth exemplary embodiment according to the present invention.
  • Fig. 33 is an exploded perspective view of the assembled elements illustrated in Fig. 32 including the air-core coil, terminal base, I-shape magnetic core and the insulating sheet.
  • Fig. 34 is a perspective view of a complete product depicted in Fig. 33.
  • Fig. 35 is a cross section of the complete product depicted in Fig. 33.
  • Fig. 36 is an exploded perspective view depicting the choke coil utilized in the fifth exemplary embodiment according to the present invention.
  • Fig. 37 is a perspective view depicting the assembled elements illustrated in Fig. 36 including the air-core coil and the terminal base.
  • Fig. 38 is a perspective view depicting the assembled elements illustrated in Fig. 36 including the air-core coil, terminal base, E-shape magnetic core.
  • Fig. 39 is a perspective view depicting the insulating sheet being further assembled with the elements illustrated in Fig. 38.
  • Fig. 40 is a perspective view of a complete product depicted in Fig. 36.
  • Fig. 41 is a cross section of the complete product depicted in Fig. 36.
  • Fig. 42 is an exploded perspective view of the choke coil utilized in the sixth exemplary embodiment.
  • Fig. 43 is a perspective view depicting the choke coil on the way of assembly.
  • Fig. 44 is a perspective view of a complete product illustrated in Fig. 42.
  • Fig. 45 is a cross section of the complete product.
  • Fig. 46 is a front view of an air-core coil before being coiled and used in the sixth exemplary embodiment.
  • Fig. 47 is an exploded perspective view of a conventional choke coil.
  • Fig. 48 is a perspective view depicting the assembled elements in Fig. 47 including the air-core coil, terminal base and E-shape magnetic coil.
  • Fig. 49 is a perspective view of a completed product depicted in Fig. 47.
  • Fig. 50 is a cross section of the completed product.
  • Fig. 51 is a top view depicting a top view of the assembled elements illustrated in Fig. 47 including the air-core coil, terminal base and E-shape magnetic core.
  • An air-core coil 20 comprises a coiled plate-type wire 21 made of flat type wire or foil type wire. More specifically, a self welding flat-type-wire coils itself and is heated to soften the self welding layer, thereby welding the layers with each other and forming the air-core coil 20.
  • These terminals 22 and 23 are to be assembled into the terminal base 24.
  • the terminal base 24 is made of insulating material such as synthetic resin, and comprises a cylinder 25, base plate 26 and a triangular protrusion 27 with which the air-core coil 20 engages. These three elements function as an insulating layer respectively.
  • the cylinder 25 of the terminal base 24 has a thickness deviation at a part, i.e., this part is thicker than other part, corresponding to the terminal 22 of the air-core coil 20, and has a vertical groove 28 which guides the terminal 22 engaged with the corresponding thicker part.
  • a terminal hole 29 through which the terminal 22 extends is punched on the base plate 26 at the lower end of the vertical groove 28 and on the triangular protrusion 27.
  • Another terminal hole 30 is punched on the base plate 26 to which the terminal 23 coupled with the outer end corresponds. Beneath the bottom face of the triangular protrusion 27, a terminal groove 31 connected to the terminal hole 29 is provided. Also beneath the base plate, a terminal groove 32 connected to the terminal hole 30 is provided.
  • the terminals 22 and 23 After assembling the air-core coil 20 with the terminal base 24, bend the protruded terminals 22 and 23, then fit them into the terminal grooves 31 and 32 so that the terminals 22 and 23 can be led out to the sides from the triangular protrusion 27 in the terminal base 24 and the corresponding end face of the base plate 26.
  • the terminals 22 and 23 are led out to the opposite directions independently, i.e., led out in 180° angles difference with each other, and whereby the choke is suitably constructed for the surface mounting.
  • a closing magnetic core 34 is incorporated with the assembled product of the air-core coil 20 and the terminal base 24.
  • the closing magnetic core 34 is formed by E-shape magnetic core 39 and I-shape magnetic core 40 both made of ferrite sintered body of manganese (Mn) system.
  • the closing magnetic core 34 comprises a center magnetic stool 35, outer magnetic walls 36 on both sides, and a common magnetic base 37.
  • a notch 38 is provided on the common magnetic base 37 of the E-shape magnetic core 39 so that the triangular protrusion 27 of the terminal base 24 can be fit thereinto.
  • a cavity 41 is provided at inside center of the outer magnetic wall 36 of the E-shape magnetic core as a guide along an outer shape of the air-core coil 20, whereby the dimension of the choke coil can be further reduced.
  • the terminal base 24 with the air-core coil 20 bend the terminals 22 and 23 along the terminal grooves 31 and 32, and fit the terminals into the grooves, then incorporate the E-shape magnetic core 39 having a cylindrical center magnetic stool 35 with the terminal base 24 from its bottom face, and fit the triangular protrusion 27 into the notch 38 so that the both elements are positioned, whereby a status illustrated in Fig. 2 is completed. Then, incorporate insulating sheet 33 with the status of Fig. 2, and further incorporate the I-shape magnetic core 40, thereby completing the choke coil illustrated in Fig. 3.
  • the choke coil is able to have a magnetic gap 42 above the center magnetic stool 35, thereby improving the current superimpose characteristics of the choke coil without increasing leakage flux from the closing magnetic core 34.
  • the insulating sheet 33 is made of polyester film, polyhenylenesulfide film, or aramid paper, and is inserted into the magnetic gap between the center magnetic stool 35 of the E-shape magnetic core 39 and I-shape magnetic core 40.
  • the thickness of the terminals 22, 23 does not affect the window height direction of the closing magnetic core 34.
  • the terminals 22, 23 can be enlarged both in thickness and sectional area, whereby the choke coil can be accommodated to a large current.
  • the air-core coil 20 is mounted on the face where the center magnetic core 35 is adjacent to the common magnetic base 37 of the closing magnetic core 34, with insulating layers such as the base plate 26 and the cylinder 25 between the air-core coil 20 and the face. Accordingly, the air-core coil 20, the terminals 22 and 23 are prevented from being damaged in assembling, and as a result, the choke coil with the higher efficiency in assembly as well as the higher reliability can be realized.
  • the plate-type terminal is employed as the terminals 22, 23 coupled to both the ends of the air-core coil 20, however, a pin-type terminal as illustrated in Fig. 6 can be also employed, whereby the choke coil can be mounted in a multi-layer printed circuit board.
  • E and I-shapes (EI-shape) magnetic cores are employed as the closing magnetic core 34 in the above embodiment, however, the TU-shape or EE-shape magnetic core as shown in Fig. 7 can be employed instead of the EI-shape.
  • the cross sectional view of the center magnetic stool 35 of the closing magnetic core 34 shows a circle in the above embodiment, it can be an ellipse or oval so that the window width of the closing magnetic core 34 can be broaden with regard to the sectional area of the center magnetic stool 35 as shown in Figs. 8 and 9.
  • a thickness of the second side can be 65-90% that of the first side without affecting the characteristics of the choke coil. As a result, a weight of the ferrite core can be reduced, and a height of the choke coil can be lowered.
  • the air-core coil 20 employs the plate-type wire 21 made of self welding flat-type-wire.
  • the plate-type wire 21 coils itself, and forms the air-core coil 20, and the air-core coil is heated so that its shape can be retained with the self welding layer.
  • external force is applied to either end of the coil to peel off, and thus the air-core coil 20 sometimes loses the coil-shape.
  • a bent portion 46 is provided on both the ends in a radial direction, i.e., the bent portion 46 at the inner end protrudes inward, and another bent portion 46 at the outer end protrudes outward.
  • This structure can prevent an insulation between the layers from being damaged by the edges of both the ends of the plate-type wire 21 of the air-core coil 20.
  • the cylinder 25 of the terminal base 24 has a thickness deviation, i.e., the corresponding part to the inner terminal 22 of the air-core coil 20 is thicker than the other part, and the vertical groove 28 is disposed on this thicker part so that the terminal 22 engaged into the groove 28 can be guided, and an engaging groove 47 is disposed within a little distance from the vertical groove 28 so that the bent portion 46 disposed at the inner end of the air-core coil 20 can be engaged with.
  • a support protrusion 49 is disposed at respective four corners of the base plate 26 with a predetermined distance from the cylinder 25.
  • An opposite face of the support protrusion 49 to the cylinder 25 is tapered (taper 50) so that the air-core coil 20 can be incorporated by guiding with this taper 50.
  • a tapered notch 51 is provided on a respective support protrusion 49, and an engaging down flap 52 is provided on the respective four corners of the insulating sheet 33. Then, the flap 52 is engaged with the tapered notch 51 thereby positioning the insulating sheet 33.
  • Another bent portion 46 disposed on the outer end of the air-core coil 20 is engaged with an end face of one of the four support protrusions 49 provided on the base plate 26.
  • the E and I-shapes magnetic cores 39 and 40 are used as the closing magnetic core 34.
  • a cavity portion 44 is provided in order to give a relief to the inner terminal 22 as well as a notch 43 is provided on an opposite edge to the notch 38 of the E-shape magnetic core 39 in order to give a relief to the outer terminal 23.
  • the upper end of the terminal 22 hits the lower face of the I-shape magnetic core 40 whereby I-shape magnetic core 40 cannot be assembled with the E-shape magnetic core 39.
  • the cavity portion 44 is provided as shown in Fig. 22, the upper end of the terminal 22 gets a relief so that the I-shape magnetic core 40 can be assembled firmly with the E-shape magnetic core 39.
  • the notch 43 on the I-shape magnetic core 40 also functions as well when the terminal 23 protrudes upward.
  • the air-core coil 20 having an ellipse inner shape or an oval inner shape is incorporated with the terminal base 24 as shown in Fig. 24 through the following steps: First, a) incorporate the bent portion 46 of the air-core coil 20 with the terminal base 24 by engaging the bent portion 46 with the groove 47 as well as the end face of protrusion 49, second, b) engage the terminals 22, 23 which extends downward through respective holes 29, 30 punched in the terminal base 24 with respective grooves 31, 32, then pull out the terminals 22, 23 to an opposite side with each other, third, c) mount the E-shape magnetic core 39 to the terminal base 24 from the bottom of the base 24 as shown in Fig.
  • the choke coil having the above structure has a lot of advantages, e.g., 1) firm positioning of the air-core coil 20 as well as the insulating sheet 33 is achieved with ease, 2) a number of defects in assembling the magnetic cores can be reduced.
  • the air-core coil 20 utilized in the above structure is produced through the following steps: First, a) form a bent portion 46 by bending a first end of the plate-type wire 21 at a right angle as shown in Figs. 17A and 17B, meanwhile, the plate-type wire is made of self welding flat-type-wire, second, b) remove an insulating layer from two parts located within a limited distance from both ends of the wire 21 so that the two parts expose conductive material, third, c) connect the terminals 22, 23 to the exposed parts by calking or welding, then, d) mount a spacer 48 to respective rear faces of the connected parts as shown in Fig. 21 so that a short circuit (A) as shown in Fig. 20 can be prevented.
  • a burr is produced on the face opposite to the connected part of the terminals, the burr causes the short circuit (A), and, e) coil the plate-type wire and heat the wire to weld each other, finally, f) form another bent portion 46 by bending a second end of the platetype wire (i.e., the end of the outer most turn) as shown in Fig. 18.
  • the bent portions 46 and the extended portions 45 are not necessarily at the ends of air-core coil 20, the structure can be modified as shown in Fig. 19.
  • the terminal base 24 is described that the cylinder 25 and the base plate 26 are in one molding, however, those two elements can be individual and coupled each other by a mechanical method or with bond.
  • the air-core coil 20 can be directly wound to the cylinder, and then the base plate 26 is assembled with the cylinder. This method can improve the production efficiency.
  • two cavity portions 44 as show in Fig. 27 can be provided in order to give a relief to the edges of the terminals 22, and 23.
  • a hole 44b giving a relief to the terminal 22 can be provided as shown in Fig. 28.
  • the third exemplary embodiment is described hereinafter by referring to Figs. 29-31.
  • the basic structure is same as that of the second exemplary embodiment, thus different points are only described here.
  • the cylinder 25 of the terminal base 24 has a thickness deviation at a part, i.e., this part is thicker than other part, corresponding to the inner terminal 22 of the air-core coil 20, and has a vertical groove 28 which guides the terminal 22 engaged with the corresponding thicker part.
  • a terminal hole 29 through which the terminal 22 extends is punched on the base plate 26 and an annexed square protrusion 55 both are provided at the lower end of the vertical groove 28.
  • Another terminal hole 30 is punched on the base plate 26 to which the terminal 23 coupled with the outer end of the air-core coil corresponds.
  • the air-core coil 20 is assembled into the terminal base 24, and then the closing magnetic core 34 is assembled thereto.
  • This closing magnetic core 34 comprises the E-shape magnetic core 39 and the I-shape magnetic core 40.
  • terminal holes 58 and 59 are punched to accept the terminals 22 and 23 which extend from the bottom side of the air-core coil 20.
  • terminal grooves 60 and 61 are provided adjacent to the holes 58 and 59.
  • the air-core coil 20 is assembled into the terminal base 24, and the square protrusion 55 is fit into the through hole 56 punched on the common magnetic base 37 of the E-shape magnetic core 39 for positioning. Then, the terminals 22 and 23 extended from the bottom side of the air-core coil 20 is led out from the terminal holes 58 and 59.
  • the insulating plate 57 is mounted beneath the bottom of the E-shape magnetic core 39. The terminals 22 and 23 extended from the bottom face of the insulating plate are bent so that the terminals 22 and 23 can be fit into the terminal grooves 60 and 61, and then, the terminals are led out from sides of the insulating plate 57. Finally, the insulating sheet 33 is assembled and the I-shape magnetic core 40 is assembled thereto, and the choke coil is completed as shown in Figs. 30 and 31.
  • the choke coil produced in the above structure has the following advantages, 1) a firm positioning of the air-core coil 20, the terminals 22 and 23 can be achieved, and 2) the closing magnetic core 34 is insulated from the mounting substrate. As a result, a choke coil suitable for being mounted onto the substrate can be obtained.
  • the fourth exemplary embodiment is described hereinafter by referring to Figs. 32-35.
  • the basic structure is same as that of the second exemplary embodiment, thus different points only are described here.
  • the support protrusions 49 disposed on each corner of the base plate 26 do not have a tapered notch 51 which could position the insulating sheet 33, and only a taper 50 is provided instead.
  • the taper 50 guides the air-core coil 20 when the air-core coil 20 is assembled.
  • the notch 38 is provided on the I-shape magnetic core 40 of the closing magnetic core 34.
  • the notch 43 is provided on an edge of the E-shape magnetic core 39, and the cavity portion 44 is provided inside of the E-shape magnetic core 39.
  • the insulating sheet 33 does not have the flap 52 for positioning, but has a hole 62 corresponding to the center magnetic stool 35 instead.
  • the choke coil illustrated in Figs. 34 and 35 are assembled through the following steps: First, a) incorporate the air-core coil 20 with the I-shape magnetic core 40, second, b) bend the terminals 22 and 23 and fit them into the terminal base 24 to join the air-core coil 20 to the triangular protrusion 27, third, c) fit the triangular protrusion 27 into the notch 38 for positioning, then, d) fit the hole 62 of the insulating sheet 33 into the center magnetic stool 35 of the E-shape magnetic core 39, and finally, e) incorporate the E-shape magnetic core 39 with the terminal base 24 by fitting the center magnetic stool 35 into the cylinder 25, which ensures the positioning of the E-shape magnetic core 39.
  • the choke coil illustrated in Figs. 34 and 35 is thus completed.
  • This structure has the following advantages: 1) the I-shape magnetic core 40 is automatically positioned by the terminal base 24, 2) the insulating sheet 33 is positioned by the center magnetic stool 35 of the E-shape magnetic core 39. These advantages profit the choke coil when it is manufactured.
  • the fifth exemplary embodiment is described hereinafter by referring to Figs. 36-41.
  • the air-core coil 20, closing magnetic core 34, and insulating sheet 33 have the same structures as those in the second exemplary embodiment, while only the terminal base 24 has a different structure.
  • the terminal base 24 to which the air-core coil 20 is mounted shapes into a case comprising the cylinder 25, the base plate 26 and an insulating wall 63.
  • the insulating wall 63 functions as an insulating layer between the air-core coil 20 and both the outer magnetic walls 36, and is disposed on the outer edge of the base plate 26.
  • the choke coil illustrated in Figs. 40 and 41 is assembled through the following steps: First, a) incorporate the air-core coil 20 with the terminal base 24 shaped like a case, second, b) bent the terminals 22 and 23, third, c) insert the cylinder 25 into the center magnetic stool 35 of the E-shape magnetic core 39, the assembled product up to this point is illustrated in Fig. 38, and then, d) position the insulating sheet 39 on the terminal base 24 as shown in Fig. 39, finally, e) incorporate the I-shape magnetic core 40 thereon, and complete the choke coil.
  • the terminal base 24 has the insulating wall 63 on the outer edge of the base plate 26, and the terminal base 24 is shaped like a case.
  • This structure thus has the following advantage: the outer turn of air-core coil 20 is insulated from the outer magnetic wall 36 of the closing magnetic core 34, whereby a damage to the air-core coil 20 in the assembly process can be prevented, and as a result, work efficiency and product reliability are improved.
  • the air-core coil 20 in those Figs. are made of flat type wire or foil type wire 21.
  • the wire coils itself, and forms the air-core coil 20.
  • Plate-type terminals 64 and 65 are connected to the plate-type conductor 21 by ultrasonic bonding or welding at places near to both the ends of the conductor 21 as shown in Fig. 46.
  • the terminals 64 and 65 comprises a first part having a width B which is connected to the conductor 21 and a second part having the wider width C.
  • a taper 66 is formed at respective boundary parts between the first and second parts in order to absorb the width difference. Since led sides of the terminals 64 and 65 have a wider area, the more stable mounting can be expected and a heat dissipation of the air-core coil 20 is improved.
  • the taper 66 smoothes a current running on the terminals 64 and 65 as well as increases the strength of the terminals against bending force. Thanks to the ultrasonic bonding or welding employed to connecting the terminals 64 and 65 to the plate-type conductor 21, the connection cannot be broken due to the heat applied to the circuit board during mounting process.
  • the air-core coil 20 coupled to the terminals 64 and 65 is molded into the terminal base 24 by insulating synthetic resin, which forms a coil part 67.
  • the triangular protrusion 27 is provided on one side of a bottom face, a protrusion 68 is provided on both the end faces of the upper face, and a cavity is provided on both the sides so that the terminals 64 and 65 are fit the cavities when the terminals are bent.
  • the closing magnetic core 34 is incorporated with the coil part 67.
  • the closing magnetic core 34 comprises E-shape magnetic core 39 and I-shape magnetic core 40 both made of manganese ferrite sintered body.
  • the notch 38 is provided so that the triangular protrusion 27 can be fit therein.
  • a notch 70 is provided on the edges opposite to each other so that the protrusions 68 provided on the terminal base 24 can be fit therein.
  • the terminal 64 coupled to the inner face of the air-core coil 20 is led out with a slant so that the terminal 65 coupled to the outer face of the air-core coil 20 can be led out at the bottom of the terminal base 24 with an identical form to the terminal 64, thereby both the terminals do not have any difference in direction when the choke coil is mounted to the substrate. As a result, mounting efficiency is improved.
  • the choke coil illustrated in Figs. 44 and 45 is assembled through the following steps: First, a) incorporate the E-shape magnetic core 39 having the cylindrical center magnetic stool 35 with the terminal base 24 (i.e., the coil part 67) from its bottom face, second, b) fit the triangular protrusion 27 into the notch 38 for ensuring the positioning, third, c) fit the protrusion 68 of the terminal base 24 into the notch 70 so that the I-shape magnetic core 40 is incorporated with the terminal base 24, and finally, d) bend upward the terminals 64 and 65 led out from the bottom face of the terminal base 24 to fit into the cavity 69 provided on the side faces of the terminal base 24.
  • the choke coil is thus completed.
  • the above structure has the following advantages: 1) the air-core coil 20 is mounted on the face contacted to the closing magnetic core 34 via an insulating layer because the surface of air-core coil 20 is molded by insulating synthetic resin, as a result, no damage is expected to the air-core coil 20, the terminals 64 and 65 in the assembly process.
  • heat dissipation of the air-core coil 20 is improved, and the size thereof as well as a number of components can be reduced, 2) since the positioning is achieved between the protrusion 68 of the terminal base 24 and the notch 70 of the I-shape magnetic core 40, assembly efficiency and product reliability are improved, and 3) because the terminals 64 and 65 are fit into the cavity 69 on the side face of the terminal base 24, a mounting space on the mounting substrate can be reduced.
  • the choke coil as shown in Fig. 43 can be mounted depending on a certain condition.
  • the notch 38 accepting the triangular protrusion 27 can be provided on the I-shape magnetic core 40.
  • the notch 70 accepting the protrusion 68 of the terminal base 24 can be provided on the E-shape magnetic core.
  • the choke coil of the present invention comprises the following elements: (a) a closing magnetic core including (a-1) a center magnetic stool, (a-2) outer magnetic walls and (a-3) a common magnetic base, (b) an air-core coil coiling a plate-type wire made of flat-type wire or foil-type wire to form itself, the air-core coil being mounted to the center magnetic stool of the closing magnetic core, where two terminals are coupled to respective ends of the plate-type wire of the air-core coil, and at least one of the terminals disposed at an inner turn of the air-core coil is led out to outside through a notch or an opening provided on either side of the common magnetic base of the closing magnetic core.
  • the thickness of the inside terminal of the closing magnetic core does not influence a window height of the closing magnetic core, thereby eliminating a dead space along the window height direction, increasing a space factor, lowering the window height of the closing magnetic core.
  • the thickness of the inside terminal can be increased, i.e., the sectional area of the terminal can be widened to accommodate to a larger current.
  • the choke coil of thinner and lower in size and being accommodated to a larger current can be produced.
  • the air-core coil when the air-core coil is mounted on a face contacted to the closing magnetic core via an insulating layer, the air-core coil and the terminals are prevented from damages in assembling. As a result, the choke coil of the better efficiency in assembly and the higher reliability can be produced.
EP97909597A 1996-10-24 1997-10-23 Drosselspule Expired - Lifetime EP0869518B1 (de)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
JP281965/96 1996-10-24
JP281963/96 1996-10-24
JP8281965A JPH10125545A (ja) 1996-10-24 1996-10-24 チョークコイル
JP28196396A JP3346188B2 (ja) 1995-11-24 1996-10-24 チョークコイル
PCT/JP1997/003833 WO1998018143A1 (fr) 1996-10-24 1997-10-23 Bobine d'arret

Publications (3)

Publication Number Publication Date
EP0869518A1 true EP0869518A1 (de) 1998-10-07
EP0869518A4 EP0869518A4 (de) 1999-12-29
EP0869518B1 EP0869518B1 (de) 2008-12-10

Family

ID=26554401

Family Applications (1)

Application Number Title Priority Date Filing Date
EP97909597A Expired - Lifetime EP0869518B1 (de) 1996-10-24 1997-10-23 Drosselspule

Country Status (5)

Country Link
US (1) US6774755B2 (de)
EP (1) EP0869518B1 (de)
CN (1) CN1234137C (de)
DE (1) DE69739156D1 (de)
WO (1) WO1998018143A1 (de)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6392525B1 (en) 1998-12-28 2002-05-21 Matsushita Electric Industrial Co., Ltd. Magnetic element and method of manufacturing the same
US7215229B2 (en) 2003-09-17 2007-05-08 Schneider Electric Industries Sas Laminated relays with multiple flexible contacts

Families Citing this family (42)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1022750A1 (de) * 1999-01-22 2000-07-26 Ecole Polytechnique Federale De Lausanne Diskretes elektronisches induktives Bauteil, und Herstellungsverfahren solcher Bauteile
JP2002208524A (ja) * 2001-01-10 2002-07-26 Sony Corp トランス装置
DE10148133A1 (de) * 2001-09-28 2003-04-24 Ascom Energy Systems Ag Bern Flachtransformator mit gesteckten Sekundärwicklungen
EP1488432B1 (de) * 2002-03-27 2010-05-19 Commergy Technologies Limited Magnetische anordnung
JP4513805B2 (ja) * 2004-03-09 2010-07-28 パナソニック株式会社 トランス
JP4528058B2 (ja) * 2004-08-20 2010-08-18 アルプス電気株式会社 コイル封入圧粉磁心
JP4472589B2 (ja) * 2005-06-28 2010-06-02 スミダコーポレーション株式会社 磁性素子
JP4783183B2 (ja) * 2006-03-16 2011-09-28 スミダコーポレーション株式会社 インダクタ
US8164406B2 (en) * 2006-05-26 2012-04-24 Delta Electronics, Inc. Transformer
US8022801B2 (en) * 2007-02-20 2011-09-20 Seiko Epson Corporation Coil unit and electronic instrument
JP4420073B2 (ja) * 2007-07-11 2010-02-24 セイコーエプソン株式会社 コイルユニット及び電子機器
TWM346891U (en) * 2008-08-19 2008-12-11 Delta Electronics Inc Electrical conductive structure and electrical device
US9117580B2 (en) 2009-02-27 2015-08-25 Cyntec Co., Ltd. Choke
USRE48472E1 (en) 2009-02-27 2021-03-16 Cyntec Co., Ltd. Choke having a core with a pillar having a non-circular and non-rectangular cross section
US9208937B2 (en) 2009-02-27 2015-12-08 Cyntec Co., Ltd. Choke having a core with a pillar having a non-circular and non-rectangular cross section
JP4654317B1 (ja) * 2009-07-16 2011-03-16 株式会社神戸製鋼所 リアクトル
CN102339666A (zh) * 2010-07-16 2012-02-01 株式会社田村制作所 电感器
JP5149976B2 (ja) * 2011-04-06 2013-02-20 株式会社神戸製鋼所 リアクトルおよびその設計方法
JP5395852B2 (ja) * 2011-08-02 2014-01-22 太陽誘電株式会社 巻線部品用コア及びその製造方法，巻線部品
CN102522182B (zh) * 2011-12-23 2013-06-05 台达电子企业管理（上海）有限公司 磁性元件
TWI436380B (zh) * 2012-02-01 2014-05-01 Delta Electronics Inc 磁性組件及其基座
US8917524B2 (en) * 2012-02-06 2014-12-23 General Electric Company Multi-function inductor and manufacture thereof
DE102012202472B4 (de) * 2012-02-17 2018-03-01 Siemens Aktiengesellschaft Vorrichtung zur kontaktlosen Übertragung von Energie auf eine korrespondierende Vorrichtung
JP5929401B2 (ja) * 2012-03-26 2016-06-08 Tdk株式会社 平面コイル素子
US9087634B2 (en) 2013-03-14 2015-07-21 Sumida Corporation Method for manufacturing electronic component with coil
US9576721B2 (en) * 2013-03-14 2017-02-21 Sumida Corporation Electronic component and method for manufacturing electronic component
TWI451457B (zh) * 2013-05-03 2014-09-01 Delta Electronics Inc 初級側模組及其適用之變壓器
CN104240912A (zh) * 2013-06-19 2014-12-24 台达电子工业股份有限公司 变压器结构
JP6413096B2 (ja) * 2014-01-30 2018-10-31 パナソニックＩｐマネジメント株式会社 コイル部品
DE102014207140A1 (de) * 2014-04-14 2015-10-15 Würth Elektronik iBE GmbH Induktionsbauteil
JP6397714B2 (ja) * 2014-10-03 2018-09-26 Fdk株式会社 コイル装置
JP2017069460A (ja) * 2015-09-30 2017-04-06 太陽誘電株式会社 コイル部品及びその製造方法
CN106803455B (zh) * 2015-11-26 2019-07-26 乾坤科技股份有限公司 平面型电抗器
DE102016209613A1 (de) * 2016-06-01 2017-12-07 Würth Elektronik eiSos Gmbh & Co. KG Montagesatz für eine Drossel und Drossel
TWI616906B (zh) * 2017-03-01 2018-03-01 Yujing Technology Co Ltd Resonant transformer with leakage inductance adjustment
KR101952867B1 (ko) * 2017-03-30 2019-02-27 삼성전기주식회사 코일 부품 및 그 제조방법
JP7075185B2 (ja) * 2017-04-27 2022-05-25 太陽誘電株式会社 コイル部品及び電子機器
JP6869796B2 (ja) * 2017-04-27 2021-05-12 太陽誘電株式会社 コイル部品
US11114232B2 (en) 2017-09-12 2021-09-07 Raycap IP Development Ltd Inductor assemblies
US11670448B2 (en) * 2018-05-07 2023-06-06 Astronics Advanced Electronic Systems Corp. System of termination of high power transformers for reduced AC termination loss at high frequency
CN114078623A (zh) * 2020-08-20 2022-02-22 Tdk株式会社 线圈部件以及搭载其的开关电源装置
EP4095871A1 (de) * 2021-05-28 2022-11-30 Solum Co., Ltd. Spulenstruktur, leistungsfaktorkorrekturschaltung mit der spulenstruktur und stromversorgung mit der leistungsfaktorkorrekturschaltung

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2401574A1 (de) * 1974-01-14 1975-07-17 Siemens Ag Schalenkernspule
US4507640A (en) * 1982-11-26 1985-03-26 Westinghouse Electric Co. High frequency transformer
DE3817890A1 (de) * 1987-05-27 1988-12-15 Murata Manufacturing Co Spule

Family Cites Families (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5558018U (de) * 1978-10-12 1980-04-19
JPS615779Y2 (de) * 1979-09-25 1986-02-21
JPS5933810A (ja) * 1982-08-20 1984-02-23 Toshiba Corp 箔巻変圧器
JPS6078123U (ja) * 1983-11-02 1985-05-31 阪神エレクトリツク株式会社 分割巻型コイルのボビン
JPH0314021Y2 (de) * 1984-09-07 1991-03-28
JPS6384915U (de) * 1986-11-21 1988-06-03
JPH0632654Y2 (ja) * 1989-03-11 1994-08-24 ティーディーケイ株式会社 コイル部品
JP2520104Y2 (ja) * 1990-11-15 1996-12-11 松下電器産業株式会社 トランス
JPH0655228U (ja) * 1991-02-20 1994-07-26 コーセル株式会社 チョークコイル
US5175525A (en) * 1991-06-11 1992-12-29 Astec International, Ltd. Low profile transformer
JP2566052Y2 (ja) * 1992-01-27 1998-03-25 株式会社トーキン トランス
JP2619847B2 (ja) * 1992-09-25 1997-06-11 東光株式会社 昇圧トランスの製造方法
JPH06204053A (ja) * 1992-12-28 1994-07-22 Tokin Corp モールドトランス
JP2540856Y2 (ja) * 1993-06-04 1997-07-09 東光株式会社 昇圧トランス
JP3139268B2 (ja) * 1994-03-30 2001-02-26 松下電器産業株式会社 チップインダクタ
JPH07320961A (ja) * 1994-05-24 1995-12-08 Tdk Corp 表面実装型トランス
JPH08138940A (ja) * 1994-11-04 1996-05-31 Murata Mfg Co Ltd 積層型コイル
JPH08172017A (ja) * 1994-12-15 1996-07-02 Tamura Seisakusho Co Ltd 薄型トランス
JP3063557B2 (ja) * 1995-02-03 2000-07-12 株式会社村田製作所 チョークコイル

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2401574A1 (de) * 1974-01-14 1975-07-17 Siemens Ag Schalenkernspule
US4507640A (en) * 1982-11-26 1985-03-26 Westinghouse Electric Co. High frequency transformer
DE3817890A1 (de) * 1987-05-27 1988-12-15 Murata Manufacturing Co Spule

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO9818143A1 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6392525B1 (en) 1998-12-28 2002-05-21 Matsushita Electric Industrial Co., Ltd. Magnetic element and method of manufacturing the same
US7215229B2 (en) 2003-09-17 2007-05-08 Schneider Electric Industries Sas Laminated relays with multiple flexible contacts

Also Published As

Publication number Publication date
US20020067237A1 (en) 2002-06-06
CN1234137C (zh) 2005-12-28
CN1206491A (zh) 1999-01-27
US6774755B2 (en) 2004-08-10
EP0869518B1 (de) 2008-12-10
DE69739156D1 (de) 2009-01-22
EP0869518A4 (de) 1999-12-29
WO1998018143A1 (fr) 1998-04-30

Similar Documents

Publication Publication Date Title
EP0869518A1 (de) Drosselspule
EP0939412B1 (de) Induktive Bauelemente und segmentierte Spulen dafür
US5760669A (en) Low profile inductor/transformer component
CN102449709B (zh) 表面安装磁性装置
JP2000269050A (ja) コモンモードチョークコイル
JP3489553B2 (ja) 薄形トランス
JP3707460B2 (ja) コイル部品
JPH11176660A (ja) コイルを含む電気回路装置
JP3173654B2 (ja) インダクタンス素子
JP3440869B2 (ja) チョークコイル
JPH08153630A (ja) トランス
JP3707461B2 (ja) コイル部品の製造方法
US6138344A (en) Methods of manufacturing a magnetic device and tool for manufacturing the same
KR101858117B1 (ko) 이중 나선형 트랜스포머
KR200495510Y1 (ko) 슬림형 트랜스포머
US11538625B2 (en) Coil device
CN218918620U (zh) 一种贴片磁性元件
JPH1154335A (ja) インダクタンス素子
JPH1197259A (ja) 薄形コイル部品
JP2531575Y2 (ja) 薄型トランス
JP3512758B2 (ja) 小型トランス
JP4341096B2 (ja) チョークコイル
JP3452963B2 (ja) 薄型変成器と同薄型変成器の製造方法及び同薄型変成器の使用方法
JPH10149931A (ja) チョークコイル
JP3413615B2 (ja) 電気部品

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 19980720

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): DE FR GB

A4 Supplementary search report drawn up and despatched

Effective date: 19991115

AK Designated contracting states

Kind code of ref document: A4

Designated state(s): DE FR GB

17Q First examination report despatched

Effective date: 20030827

17Q First examination report despatched

Effective date: 20030827

GRAP Despatch of communication of intention to grant a patent

Free format text: ORIGINAL CODE: EPIDOSNIGR1

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAS Grant fee paid

Free format text: ORIGINAL CODE: EPIDOSNIGR3

GRAA (expected) grant

Free format text: ORIGINAL CODE: 0009210

RAP1 Party data changed (applicant data changed or rights of an application transferred)

Owner name: PANASONIC CORPORATION

AK Designated contracting states

Kind code of ref document: B1

Designated state(s): DE FR GB

REG Reference to a national code

Ref country code: GB

Ref legal event code: FG4D

REF Corresponds to:

Ref document number: 69739156

Country of ref document: DE

Date of ref document: 20090122

Kind code of ref document: P

PLBE No opposition filed within time limit

Free format text: ORIGINAL CODE: 0009261

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT

26N No opposition filed

Effective date: 20090911

REG Reference to a national code

Ref country code: GB

Ref legal event code: 746

Effective date: 20091215

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: GB

Payment date: 20131023

Year of fee payment: 17

Ref country code: FR

Payment date: 20131009

Year of fee payment: 17

PGFP Annual fee paid to national office [announced via postgrant information from national office to epo]

Ref country code: DE

Payment date: 20141014

Year of fee payment: 18

GBPC Gb: european patent ceased through non-payment of renewal fee

Effective date: 20141023

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: GB

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20141023

REG Reference to a national code

Ref country code: FR

Ref legal event code: ST

Effective date: 20150630

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: FR

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20141031

REG Reference to a national code

Ref country code: DE

Ref legal event code: R119

Ref document number: 69739156

Country of ref document: DE

PG25 Lapsed in a contracting state [announced via postgrant information from national office to epo]

Ref country code: DE

Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES

Effective date: 20160503